Electromagnetic relay with one-piece support for core and armature



1965 w. R. BAUER 3,213,230

ELECTROMAGNETIC RELAY WITH ONE-PIECE SUPPORT FOR CORE AND ARMATURE Filed March 5, 1963 2 Sheets-Sheet l 7 6p? FIGJ 3 J24 J14 J16 INVENTOR. WERNER ROBERT BAUER HIS ATTORNEYS Oct. 19, 1965 w. R. BAUER 3,213,230

ELECTROMAGNETIC RELAY WITH ONE-PIECE SUPPORT FOR CORE AND ARMATURE Filed March 5, 1963 2 Sheets-Sheet 2 50 7 w} L J 42 HIS ATTORNEYS United States Patent 3 213,230 EILETR()It IAGNETIC RELAY WITH ONE-PIECE SUPIQRT FOR CORE AND ARMATURE Werner Robert Bauer, Columbus, Ohio, assignor to Robertshaw Controls Company, a corporation of Delaware I Filed Mar. 5, 1963, Ser. No. 262,916 Claims. (Cl. 200-87) This invention relates to an electromagnetic relay structure, and particularly to a relay structure which may be manufactured at low cost, and yet provide a satisfactory relay for a large proportion of possible uses of the relay structure.

The relay may include a blank of magnetic metal sheet having an armature supporting section at one end, a core forming section at the other end, and a base forming section intermediate the other two sections. The blank may be bent at a right angled structure to hold the armature supporting section substantially at right angles to the base forming structure. The blank may also be bent at another right angle structure to hold a hollow columnar or space confining core member, which is formed from the core forming section of the blank, substantially at right angles to the base forming section. A core supporting zone may be located in the blank between the base forming section and the core forming section, where the second right angle structure is formed to hold the core at right angles to the base. 7

Another feature of this invention is that the core which is formed from the blank receives sufiicient metal and surface from the blank to provide a satisfactory total or average permeability to the core for a large percent of uses, so that the relay may be manufactured at a very relatively low cost without the addition of laminations or the like in the core in the manner to produce a satisfactory relay at such low cost. However, when it is desired to improve the efiiciency of the relay for more demanding situations, the core may be provided with laminations and/or additional metal in the blank, to enhance the permeability of the core.

Another feature of this invention is that the same blank may be used to mount a plurality of diiferent switch structures or other devices to be actuated by the relay without altering the shape or structure of the blank. For example, a box-like, plunger operated, switch structure may be attached to the rear of the armature supporting section of the relay, so the plunger can be operated by the armature without change in either the blank or the armature. Alternatively the same blank may be provided with a bracket which may be attached to the rear of the armature supporting section, and the bracket may support a different type of switch structure or other mechanism to be actuated. Such other switch structure may be a blade construction in which the body of the switch structure is supported by the bracket, and one or more of the blades of the switch are connected to the movable end of the armature, by a suitable electrical insulating member, if desired.

An improved armature hinging construction has been provided between the armature and the armature supporting members, which permits easy assembly of the armature with the support, and which provides superior magnetic flux transmission or stress which avoids residual magnetism, which otherwise might interfere with proper hinging of the armature.

Other features are apparent from this description, the appended claimed subject matter, and/or from the accompanying drawings, in which:

FIGURE 1 is a side elevation of one embodiment of the invention.

Patented Oct. 19, 1965 FIGURE 2 is a vertical cross-section along the line 2-2 of FIGURE 1.

FIGURE 3 is a horizontal cross-section along the line 3-3 of FIGURE 2.

FIGURE 4 is a perspective view of the combined armature support, base member and core member of the embodiment of FIGURE 1. v V

FIGURE 5 is a plan view of the armature of the em bodiment of FIGURE 1.

FIGURE 6 is a plan view of a blank suitable for forming the embodiment of FIGURE 4.

FIGURE '6A shows another embodiment of a portion of FIGURE 6.

FIGURE 7 is a perspective view showing another embodiment of a core member which is somewhat similar to the core member shown in FIGURE 4.

FIGURE 8 is a view of another embodiment of a switch actuating member of an armature similar to that shown in FIGURE 1.

FIGURE 9 is a plan View of the portion of the armature shown in FIGURE 8. I

FIGURE 10 is a view of an embodiment having a different form of switch structure from that shown in FIGURE 1. 7

FIGURE 11 is a perspective view of another embodiment of a combined field piece and core member.

FIGURE 12 is a cross-section along line 12-12 of FIGURE 11.

FIGURE 13 is a plan view of a blank suitable for forming the embodiment of FIGURES l1 and 12.

FIGURE 14 is a perspective view of another embodiment of a combined armature support, base member and core member.

FIGURE 15 is a vertical cross-section along the line 15-15 of FIGURE 12.

FIGURE 16 is a plan view of another embodiment of a portion of a combined armature support, base memher and a core member.

FIGURE 17 is a cross-section along the line 17-17 of FIGURE 16.

FIGURE 18 is a perspective view of another embodiment of a portion of a combined armature support, base member and core member.

The electromagnetic relay structure of this invention, for example, may be made from a blank of magnetic metal sheet 10, FIGURE 6. The blank may have an armature support forming section 12 at one end of the blank and a core forming section 14 at the other end of the blank. A base forming section 16 may be provided intermediate the sections 12 and 14. The sections 12 and 16 are not separated by any discernible boundary in the original fiat blank shown in FIGURE 6, but they are nevertheless separated by the structure of the blank along the line beteween the arrows 18 and 20 where a right angled structure 22 is to be formed, as shown in FIGURES 1, 4, and :10.

An inwardly directed slit construction, such as slits 24 and 26 may extend from the edge construction of the blank, such as at edges 28 and 30, said slit construction extending between the base forming section 16 and the core forming section 14. The slit construction may extend to a core supporting zone 32, which is part of the blank.

The blank of FIGURE 6 may be bent to form a right angle structure at 22, which holds the armature supporting section 12 substantially at right angle to the base forming section 16.

The blank of FIGURE 6 may be bent at another right angle structure 34 to hold a hollow columnar or space confining core member 36, which is formed from the material of the core forming section 14. The columnar core member 36 may be substantially at right angles to the base forming section 16 at the core supporting zone 32.

The hollow columnar member 36 may have two walls 38 and 40, which may be parallel to each other and may have a third wall 42 substantially at right angles to the walls 38 and 40 to form a core having a substantially U- shaped cross section, such as shown at the top of the core member 36 in FIGURE 4.

The slits 24 and 26 may be sufficiently relatively narrow and may have substantially parallel sides between the base section 16 and the core section 14, which slits may cooperate with the right angle structure 34 to cause the bases of the core walls 38 and 41) to be closely adjacent to and parallel with the top surface of the base section 16, as shown in FIGURE 10.

If desired, U-shaped core member 36, such as shown in FIGURES 4 and 7 may be provided with additional magnetic material surface, such as by reversely bending the corresponding walls 38a and 40a of FIGURE 16 respectively at 44 and 46 to provide reversely directed walls 48 and 50, so that the inwardly directed extensions 43- and 50 form a double thickness of wall at the original legs 38a and 40a. This increases the permeability of the core at very little extra cost.

An armature 52, of magnetic metal sheet may be formed, such as shown in FIGURE 5, and this may be hinged at 54 on the armature supporting section 12 to be pulled down, for downward rocking movement, when the magnetic coil 56 is energized, and to be released for upward rocking movement when the coil 56 is being energized.

The coil 56 may be press fitted onto the columnar member 36, and its downward movement may be limited by the offset lugs 58 on the core forming section 14.

If desired, notches 60 may be formed in the walls 38 and 40, FIGURE 7, to receive a shading ring, such as the copper ring 62 shown in FIGURE 10, or the copper ring 64 shown in FIGURE 18. Such ring tends to reduce hum and chatter.

The armature 52 may be hinged on the support 12 at the slotted construction 66, which is shown in FIGURE 6.

The innermost shelves 68 of slot 66, FIGURES 4 and 6, receive the edges 70 of the neck 72, FIGURE 5, of the armature 52. The walls 74 prevent any excessive sidewise movement of the armature at the hinge point. The walls 76 are sufficiently far apart to permit the hook members 78 of the armature to pass between such walls '76, and over shelves 79, and through the upper wide portion 81 and to hook the armature 52 in place when the armature is lowered with the edges 70 on the shelves 68.

The lower part 80 of the opening 66 is for the purpose of reducing the residual magnetism in the armature support 12.

The circular cuts 82, and the teeth 84 of the armature, FIGURE 5, are for the purpose of locking the armature 52 against leftward movement in FIGURE 3. The hook members '78 hold the armature against rightward movement in FIGURE 3. The tolerances are such that there is a slightly loose engagement, so that the armature 52 may freely rock on the shelves 68, but may not materially move sidewise.

Tongues 85, FIGURES 1, 4, 6, and 10, may be struck from the armature supporting section 12. They may be bent inward sufficiently to arrest the upward movement of the armature 52. Any type of tongue construction may be used. For example, as shown in FIGURE 6A slots 86 and 8-8 may be struck from the blank, similar to that shown in FIGURE 6, to form a tongue construction 91), with a tooth 92. The tongue 96 may then be bent over the armature 52 to arrest upward movement, in a manner similar to tongue 85.

Holes 94, FIGURE 6, may be made in the base section 16, for attaching the relay to any desired support.

Such attachment may be made by screws, rivets or the like, through the holes 94.

A switch structure may be attached to the armature supporting section 12. For example, the box-like switch structure 95 may be any suitable snap switch structure, if desired, which may be rectangular sided, and may have an electrically insulating body surrounding the switch structure. Lead-in connectors 96 may be provided for connecting the electrical circuit to the switch structure 95. The switch contacts may be opened and closed by a plunger 98 which may be downwardly spring biased, and its end may engage the tongue 101 of the armature 52. The downward spring bias of the plunger 98 is sufficient to lift the armature to the position shown in FIGURE 1 when the coil 56 is deenergized, but is insufiicient to resist the magnetic pull of the coil 56 when the coil is energized.

The armature 52 and the blank 10 may be made of Well known magnetic sheet material which is relatively soft so that it doest not retain permanently any magnetic properties but has relatively high permeability. A hard steel button 102, or the like, may be riveted in the hole 104, and may strike the wall 42 to arrest the downward motion of armature 52. The button 102 may be sutficiently hard to resist perceptible wear.

The switch box 95 may be secured by bolt and nut constructions 105, which may pass through the holes 106 in the armature supporting section 12.

If desired, the end of the armature 52 may be changed slightly, to provide a tongue 107, FIGURES 8 and 9, with an upward bend 108 to engage the plunger 98 of the switch 94. Circular cuts 110 permit a better stamping procedure, as is also the case with the circular cuts 82.

The same type of blank which is shown in FIGURE 6 may be used to accept a different type of switch construction or other member to be actuated by the armature 52, such as shown in FIGURE 10. The structure shown in FIGURE 10 may be substantially the same as has heretofore been described in connection with FIGURES 1-7, except that the switch structure 112 may be mounted on a right angled bracket 114, or the like, which may be bolted at 116 in the holes 106. Such switch structure 112 may be secured to the bracket 114 by the screws 118. The switch structure 112 may have a blade construction 120 which may be of any suitable blade type, with or without spring snap action, and which may be permanently biased at the blade 122 in the up position. The blade 122 may be connected to an electrically insulating plate 124 which may be connected to the armature 52. The connections may be made in any well known manner such as by staking, slits, etc. between the members 52, 122 and 124. The upward bias of the blade 122 may ull the armature 52 to the up position when the coil 56 is deenergized, but may yield to the magnetic pull of the coil 56 when the coil 56 is energized.

It is to be noted that the blank 10, such as shown in FIGURE 6, lends itself to producing the core structure 36 without the necessity of securing it to the base 16 by screws, bolts, rivets or the like. In addition, the core section 36 is provided with a plurality of walls, or a plurality of outer sides such as the walls 38, 40, and 42, to provide the total or average permeability required for many uses.

The core 36 has sufiicient magnetic flux carrying power because of the extensive surface as provided by the plurality of walls 38, 4t) and 42. This capacity may be sufficient for ordinary purposes without the necessity of adding any expensive laminations. However, if it should be desired to add further refinements, it is possible to insert laminations in the structure of the core 36, substantially in the same manner as illustrated in FIGURE 18, or to provide the additional walls 48 and 50 of FIGURES 16 and 17.

FIGURES 11, 12, and 13 show an embodiment in which the armature support forming section 12A may be substantially identical to the section 12 heretofore described. Section 12A is shown as terminating at 126, but it is to be understood that section 12A may continue beyond this point in substantially the same manner as is shown in section 12. This combination is indicated by the dotted line 128 in FIGURES 1l-13. The base forming section 16A may be bent at right angles to the section 12A at a line such as is indicated by the arrows 18A and 20A to form the right angle structure 22A in a manner analogous to similarly identified members (without the letter suffixes) in FIGURES 1-10. However, the slit construction in FIGURES 11-13 may include the slits 24A and 26A, which extend from the edge construction of the blank A, which slit construction extends to the core supporting zone 32A. A right angle structure at 34A and 34B permits the wings 14A and 14B to be bent at right angles, at 34A and 34B to form the upwardly directed core 36A. The wings 14A and 1413 may be curved into semi-cylindrical Walls, which may form a substantially cylindrical core, which, if desired, may be provided with the shading ring receiving slots WA, if desired.

The upper part of the armature supporting structure 12A may be substantially the same as the upper part of the armature supporting structure 12 in FIGURES l-lO. The upper part of structure 12A may be substantially the same as any of the corresponding structures in FIGURES 1-10. The illustration in FIGURES 11-13 has been-terminated at 126 in the illustration for the sake of avoiding repetition in description and illustration. The extension is indicated by the dotted lines 128 to indicate that the upper part of the armature supporting structure 12A may be the same as in 12. A tongue construction 129 may extend beyond the column 36A, to increase the supporting area of the relay construction.

In the embodiment shown in FIGURES 14 and 15, the wings 14C and 14D may be somewhat narrower than those illustrated in FIGURES 11-13. The walls 14C and 14D may remain in fiat condition to form two parallel flat walls which form a columnar core having a substantial amount of permeability. If desired, the walls of the embodiment of FIGURES 14 and 15 may be bent at 34C and at 22C and may have an extension 129C, substantially corresponding to similar structures in FIGURES 11-13. If desired, laminations may be placed between the core walls to increase the permeability in a manner substantially the same as in FIGURE 18.

In FIGURE 18, the armature supporting wall 12E and the base forming wall 16E may be substantially the same as similarly described constructions in connection with FIGURES 11-15. The core forming wings ME and MP may be bent at ME. A core supporting zone 32E is provided substantially the same as zone 32A and the tongue 129E may be somewhat different in shape, but for the same purpose as the tongue 129 and 129C. The laminations 130 may be pla-ced between walls 14B and 14F and may be secured by rivets or the like 132. Slots 60F may be provided to receive the shading ring 64 of copper or the like.

In the embodiment of FIGURES 16 and 17 the armature supporting wall 126 and the base forming portion 166 may be substantially the same as has been previously described with any of the similar structures of the other embodiments, and the core structure may be as previously described. Slots 60G may be provided for a shading ring, if desired. Such shading ring may be rectangular, as in FIGURE 18 or circular with a central web, which web is received in the slots.

It is thus to be seen that a new and useful electromagnetic relay structure, and method of producing the same have been provided.

While the form of the invention now preferred has been disclosed as required by statute, other forms may be used, all coming within the scope of the claimed subject matter which follows.

What is claimed is:

1. A homogenous electromagnetic relay structure having a straight armature supporting section, a straight base section and a core member made from a blank of magnetic metal sheet having a substantially rectangular armature support forming section at one end, a substantially rectangular core forming section at the other end, and a substantially rectangular base forming section intermediate said first named sections, said blank having a pair of relatively narrow inwardly directed slits extending from the edge construction of said blank between said base forming section and said core forming section and extending to a core supporting Zone in said blank, said blank having a substantially right angled structure holding said armature supporting section substantially at right angles to said base forming section, said blank having a right angled structure holding a hollow columnar core member which is formed from said core forming section substantially at right angles to said base forming section at said core supporting zone, said core member having two parallel walls with their bases closely adjacent to and parallel with the top surface of said base section.

2. An electromagnetic relay structure comprising: a magnetic metal homogeneous sheet having two substantially right angled bends to form a substantially fiat armature supporting section, a substantially flat base section, and a columnar core forming section, said core forming section forming a plurality of outer sides of said core forming section from said homogeneous sheet; an armature hinged on said armature supporting section; and a magnetic coil around said core forming section, said substantially flat armature supporting section having an armature receiving opening with an upper relatively wide armature inserting portion and a lower relatively narrow armature supporting portion, said armature having armature ends, one of said armature ends being inserted through said armature inserting portion and being supported on said armature supporting portion, a pair of bolt openings on said flat armature supporting section above said armature, and a switch supported by bolts passing through said bolt openings and having switch actuating means actuated by one of said armature ends.

3. A relay structure according to claim 2 in which said switch actuating means is actuated by the armature end which is inserted through said armature inserting portion.

4. A relay structure according to claim 2 in which said switch is supported by a bracket which is supported by said bolts and in which said switch actuating means is actuated by the armature end which is not inserted through said armature inserting portion.

5. An electromagnetic relay structure comprising: a magnetic metal homogeneous sheet having two substantially right angled structures to form a substantially flat armature supporting section, a substantially flat base section substantially at right angles to said armature supporting section and a space confining walled core forming section substantially at right angles to said base sec tion, an armature hinged on said armature supporting section, and a magnetic coil around said core forming section, said substantially flat armature supporting section having an armature receiving opening, said armature having armature ends, one of said armature ends being inserted through said armature inserting portion and being supported on said armature supporting portion, switch supporting means on said flat armature supporting section above said armature, and a switch supported by said switch supporting means and having switch actuating means actuated by one of said armature ends.

6. A relay structure according to claim 5 in which said switch actuating means is actuated by the armature end which is inserted through said armature inserting portion.

7. A relay structure according to claim 5 wherein said switch is supported by a bracket which is supported by said switch supporting means and in which said switch actuating means is actuated by the armature end which is not inserted through said armature inserting portion.

8. A relay structure according to claim 5 wherein said armature supporting section has a tongue construction to limit the pivoting action of said armature.

9. An electromagnetic relay structure comprising: a magnetic metal homogeneous sheet having two substantially right angled structures to form a substantially flat armature supporting section, a substantially flat base section substantially at right angles to said armature supporting section, and a multiple wall core forming section substantially at right angles to said base section, an armature hinged on said armature supporting section; and a magnetic coil around said core forming section, said armature supporting section having an armature receiving opening with an upper relatively wide armature receiving portion and a lower relatively narrow residual magnetism preventing portion, an upper relatively wide apart pair of shelves under said wide portion and a lower relatively closer together pair of shelves below said first named pair of shelves, said armature having a neck resting on said lower relatively closer together pair of shelves, and with two pairs of hooks with a pair of hooks respectively on opposite sides of said last named pair of shelves to hold said armature in place.

10. A relay structure according to claim 9 in which said core forming section has a transverse cross section in the shape of a U.

11. A relay structure according to claim 10 in which each of the legs of said U have inward reverse angled structures to form a double wall structure on each leg.

12. A relay structure according to claim 9 in which said core forming section has a substantially circular cross section.

13. An electromagnetic relay structure having an armature supporting section, a base forming section substantially at a right angle to said armature supporting section, and a core section substantially at a right angle to said base forming section, said armature supporting section having an armature receiving opening with an upper relatively wide armature receiving portion and a lower relatively narrow residual magnetism preventing portion, an upper relatively wide apart pair of shelves under said wide portion and a lower relatively closer together pair of shelves below said first named pair of shelves, an armature inserted in said armature receiving opening with a neck resting on said lower relatively closer together pair of shelves, and with two pairs of hooks with a pair of hooks respectively on opposite sides of said last named pair of shelves to hold said armature in place, and a magnetic coil surrounding said core section.

14. A relay structure according to claim 13 with said armature supporting section having a pair of tongues extending inward over said armature to arrest upward movement of said armature.

15. A relay structure according to claim 13 wherein a magnetic metal homogeneous sheet having two substantially right angled structures forms said armature supporting section, said base forming section substantialyl at a right angle to said armature supporting section, and said core section substantially at a right angle to said base forming section.

References Cited by the Examiner UNITED STATES PATENTS 1,630,116 5/27 Elrnenthaler 3l7165 1,715,135 5/29 Lambert 29551 1,981,259 11/34 Wertz 317- X 2,150,384 3/39 MacLagan 29551 2,440,888 5/48 Biggle 317165 2,450,723 10/48 Elrad 29l90 2,462,894 3/49 Price 317-165 2,602,988 7/52 Klym 29190 3,022,399 2/62 Bauer ZOO-87 FOREIGN PATENTS 1,108,457 8/55 France.

600,789 4/48 Great Britain.

OTHER REFERENCES Kahlert (German printed application), 1,113,753, Sept. 14,1961.

JOHN F. BURNS, Primary Examiner.

JOHN P. WILDMAN, LARAMIE E. ASKIN,

Examiners. 

1. A HOMOGENOUS ELECTROMAGNETIC RELAY STRUCTURE HAVING A STRAIGHT ARMATURE SUPPORTING SECTION, A STRAIGHT BASE SECTION AND A CORE MEMBER MADE FROM A BLANK OF MAGNETIC METAL SHEET HAVING A SUBSTANTIALLY RECTANGULAR ARMATURE SUPPORT FORMING SECTION AT ONE END, A SUBSTANTIALLY RECTANGULAR CORE FORMING SECTION AT THE OTHER END, AND A SUBSTANTIALLY RECTANGULAR BASE FORMING SECTION INTERMEDIATE SAID FIRST NAMED SECTIONS, SAID BLANK HAVING A PAIR OF RELATIVELY NARROW INWARDLY DIRECTED SLITS EXTENDING FROM THE EDGE CONSTRUCTION OF SAID BLANK BETWEEN SAID BASE FORMING SECTION AND SAID CORE FORMING SECTION AND EXTENDING TO A CORE SUPPORTING ZONE IN SAID BLANK, SAID BLANK HAVING A SUBSTANTIALLY RIGHT ANGLED STRUCTURE HOLDING SAID ARMATURE SUPPORTING SECTION SUBSTANTIALLY AT RIGHT ANGLES TO SAID BASE FORMING SECTION, SAID BLANK HAVING A RIGHT ANGLED STRUCTURE HOLDING A HOLLOW COLUMNAR CORE MEMBER WHICH IS FORMED FROM SAID CORE FORMING SECTION SUBSTANTIALLY AT RIGHT ANGLES TO SAID BASE FORMING SECTION AT SAID CORE SUPPORTING ZONE, SAID CORE MEMBER HAVING TWO PARALLEL WALLS WITH THEIR BASES CLOSELY ADJACENT TO AND PARALLEL WITH THE TOP SURFACE OF SAID BASE SECTION. 